Thin film with high load of active ingredient

1. A method of preparing a thin film, the method comprising:

(a) mixing a lipid, emulsifier, and solvent to provide a uniform first mixture;

(b) contacting an active ingredient with the uniform first mixture to provide a thickened second mixture;

(c) contacting a binder with the thickened second mixture to provide a slurry; and one of (d) and (e):

(d) hot extruding, casting, and condensing the slurry to provide the thin film;

(e) cooling, shearing, mixing, casting, and condensing the slurry to provide the thin film, wherein

the active ingredient is present in 30 wt. % to 65 wt. %;

the thin film having a thickness of about 0.01 mm to about 1 mm;

the thin film having a dissolution of about 30-300 seconds when placed in the mouth;

wherein at least 10 wt. % of the active ingredient is encapsulated by the lipid in the form of liposomes, micelles, or both; and

wherein the lipid is present in 4-22 wt. %, and is selected from at least one of hydroxylated lecithin and deodorized cocoa butter; and

wherein the thin film includes 0-0.1 wt. % preservative selected from at least one of benzoate salt, sorbate salt, and natamycin.

2. The method of claim 1 , wherein the mixing comprises blending, carried out at a temperature of about 130-140° F. (54.4-60° C.).

3. The method of claim 1 , wherein the contacting of the active ingredient with the uniform first mixture comprises initially contacting a non-sticky binder with the uniform first mixture, and subsequently contacting a sticky binder with the uniform first mixture.

4. The method of claim 1 , wherein the contacting of the active ingredient with the uniform first mixture comprises initially contacting microcrystalline cellulose with the uniform first mixture, and subsequently contacting pectin with the uniform first mixture.

5. The method of claim 1 , wherein the condensing comprises heating at a temperature of at least 50° F. (10° C.).

6. The method of claim 1 , further comprising contacting a powder coating with two opposing external sides of the thin film.

7. The method of claim 6 , wherein the powder coating comprises at least one of talc and microcrystalline cellulose.

8. The method of claim 1 , wherein the solvent comprises at least one of water and ethanol.

9. The method of claim 1 , wherein the solvent is present in about 2-24 wt. %.

10. The method of claim 1 , wherein the binder is present in about 4-50 wt. %.

11. The method of claim 1 , wherein the lipid is present in about 4-22 wt. %.

12. The method of claim 1 , wherein the emulsifier is present in about 3-22 wt. %.

13. A method of preparing a thin film, the method comprising:

(a) blending at a temperature of about 130-140° F. a lipid, emulsifier, and solvent to provide a uniform first mixture;

wherein the solvent comprises at least one of water and ethanol;

wherein the lipid is present in 4-22 wt. %, and is selected from at least one of hydroxylated lecithin and deodorized cocoa butter; wherein the emulsifier comprises at least one of glycerin, propylene glycol, and polyethylene glycol;

(b) contacting an active ingredient with the uniform first mixture to provide a thickened second mixture;

wherein the active ingredient is present in 30 wt. % to 65 wt. % and at least 10 wt. % is encapsulated by the lipid in the form of liposomes, micelles, or both;

(c) contacting a binder with the thickened second mixture to provide a slurry;

wherein the binder comprises at least one of pectin, microcrystalline cellulose, xanthan gum, locust bean gum, guar gum, gum arabic, gum tragacanth, gum karaya, beta glucan, glucomannan, tapioca starch, carrageenan, xanthan gum, gellan gum, alginic acid or sodium alginate, konjac gum, tara gum, chitosan, agar, maltodextrin, polyvinyl alcohol, pullulan, polycarbophil, povidone, hydroxypropyl methylcellulose, hydroxypropyl cellulose, hydroxypropyl starch, and sodium carboxymethyl cellulose;

(d) hot extruding, casting, and condensing the slurry to provide the thin film; or cooling, shearing, mixing, casting, and condensing the slurry to provide the thin film; and

(e) contacting a powder coating with two opposing external sides of the thin film;

wherein the powder coating comprises at least one of talc and microcrystalline cellulose;

the thin film having a thickness of about 0.01 mm to about 1 mm; and

the thin film having a dissolution of about 30-300 seconds when placed in the mouth; and

wherein the thin film includes 0-0.1 wt. % preservative selected from at least one of benzoate salt, sorbate salt, and natamycin.

14. The method of claim 1 , wherein the binder comprises at least one of pectin, microcrystalline cellulose, xanthan gum, locust bean gum, guar gum, gum arabic, gum tragacanth, gum karaya, beta glucan, glucomannan, tapioca starch, carrageenan, xanthan gum, gellan gum, alginic acid or sodium alginate, konjac gum, tara gum, chitosan, agar, maltodextrin, polyvinyl alcohol, pullulan, polycarbophil, povidone, hydroxypropyl methylcellulose, hydroxypropyl cellulose, hydroxypropyl starch, and sodium carboxymethyl cellulose.

15. The method of claim 1 , wherein the emulsifier comprises at least one of glycerin, propylene glycol, and polyethylene glycol.

16. The method of claim 1 , wherein the active ingredient is present in about 30-45 wt. % of the thin film.

17. The method of claim 1 , wherein at least 50 wt. % of the active ingredient is encapsulated by the lipid.

18. The method of claim 1 , wherein the lipid encapsulates the active ingredient by the formation of liposomes.

19. The method of claim 1 , wherein the lipid encapsulates the active ingredient by the formation of multilamellar liposomes.

20. The method of claim 1 , wherein the lipid encapsulates the active ingredient by the formation of micelles.

21. The method of claim 1 , further comprising contacting a powder coating with the external sides of the thin film.